Re-sealable flexible package with reinforced perimeter

ABSTRACT

Improved packages and methods for constructing packages are provided that reduce or prevent leakage into or out of the package. In particular, the package includes a base member and a lidding member with a reinforced perimeter portion that blocks channels that may form at the interface between the base member and the lidding member from extending to the edge of the base member, such that, e.g., liquids have no path to the package exterior. The perimeter portion may be a thicker region of a first film of the lidding member (e.g., a polyethylene emulsion), or the perimeter portion may be formed using permanent adhesive. Frangible layers and/or cut lines may be defined in the material of the base member or the lidding member to allow a controlled break to occur when the lidding member is peeled away from the base member to provide access to the package contents.

BACKGROUND

The present disclosure relates in general to packaging for products, andmore particularly to packaging constructed from flexible film-basedmaterials. The disclosure is especially concerned with packages thatinclude a base member and a lidding member, where the lidding memberincludes features for preventing or minimizing leakage of the contentsof the package.

Flexible film-based materials can be used to construct packages forproducts. Such a package can include a base member, such as a rigidplastic tub or tray, composite can, or other container, and a liddingmember made of a multilayer flexible film laminate that can be peeledoff the base member to provide access to the contents of the package(e.g., meat, cheese, etc.). In some cases, the peelable portion may bedesigned to be re-adhered to the rest of the package to provide areclosing feature for storing unused contents of an opened package.Often, the contents of the package may include a liquid component, suchas juices, oils, or other liquids.

BRIEF SUMMARY

Embodiments of the invention described herein provide improved packagesand methods for constructing packages that reduce or prevent leakage ofthe liquid component of the contents to the package exterior. Inparticular, embodiments of the invention include a reinforced perimeterportion that blocks channels that may form at an adhesive interface(e.g., between the base member and the lidding member) and prevents themfrom extending to the edge of the base member, such that liquidscontained in the package have no path to the package exterior.

Accordingly, in some embodiments, a flexible package is provided thatcomprises a base member and a lidding member. The base member may definea cavity configured to receive an item therein, and the base member maycomprise a flange, where the flange defines an exterior edge. Thelidding member may be configured to be attached to the base member tocover the cavity and maintain the item within the base member. Thelidding member may be configured to be peeled away from the base memberto provide access to the cavity and may be configured to be re-sealed tothe base member.

The lidding member may comprise a first layer configured to engage theflange of the base member and extending at least to the exterior edge ofthe flange, as well as a second layer laminated to the first layer viaan adhesive layer. The adhesive layer may comprise a pressure sensitiveadhesive that is configured to separate from the first layer when atleast a portion of the lidding member is peeled away from the basemember. The lidding member may further comprise a perimeter portionadjacent an outer edge of the pressure sensitive adhesive, such that thepressure sensitive adhesive is spaced inwardly from the exterior edge ofthe flange by the perimeter portion.

In some cases, the perimeter portion is may be defined by the firstlayer. The lidding member may comprise a cut line between the pressuresensitive adhesive and the perimeter portion, and the cut line mayextend at least partially through a thickness of the first layer towardsthe base member, such that the lidding member separates from the basemember at an interface disposed between the first layer and the basemember on an outward side of the cut line and at an interface disposedbetween the pressure sensitive adhesive and the first layer at an inwardside of the cut line. In other embodiments, the lidding member maycomprise a cut line between the pressure sensitive adhesive and theperimeter portion, and the cut line may extend at least partiallythrough a thickness of the first layer towards the base member, suchthat the lidding member separates from the base member at an interfacedisposed between the first layer and the base member on an outward sideof the cut line and at an interface disposed between the pressuresensitive adhesive and the first layer at an inward side of the cutline. Moreover, the first layer and the perimeter portion may extendoutwardly past the outward edge of the flange of the base member and maydefine a break tab.

In other cases, the perimeter portion may comprise permanent adhesive. Afrangible layer may be disposed between the adhesive layer and the firstlayer. The lidding member may, in some cases, comprise a cut lineextending through a thickness of the first layer outwardly of the outeredge of the flange so as to define a break tab. The package may furthercomprise a frangible layer between the first layer and the flange of thebase member. The lidding member may comprise a cut line extendingthrough a thickness of the first layer in a location corresponding to aninterface between the pressure sensitive adhesive and the perimeterportion, and the cut line may extend at least partially through athickness of the first layer between the base member and the adhesivelayer, such that the lidding member is separable from the base member atthe frangible layer on an outward side of the cut line and at aninterface disposed between the pressure sensitive adhesive and the firstlayer at an inward side of the cut line.

The lidding member, in some cases, may further comprise an ink layerdisposed on an inner surface of the second layer between the adhesivelayer and the second layer. Additionally or alternatively, the secondlayer of the lidding member may comprise a barrier material.

In still other embodiments, a method of manufacturing a flexible packageis provided. According to the method, a base member may be formed havinga cavity configured to receive an item therein and a flange, wherein theflange defines an exterior edge. A first layer of material may belaminated to a second layer of material to form a lidding member byapplying a pressure sensitive adhesive between the first and the secondlayers, and creating a perimeter portion between the first and secondlayers that is disposed adjacent to an outer edge of the pressuresensitive adhesive. In this way, the pressure sensitive adhesive may bespaced inwardly from the exterior edge of the flange. The lidding membermay be attached to the base member at a location corresponding to theperimeter portion, such that the lidding member covers the cavity andmaintains the item within the base member. At least a portion of thelidding member may be configured to be peeled away from the base memberto provide access to the cavity and may further be configured to bere-sealed to the base member via the pressure sensitive adhesive.

In some cases, a cut line may be created through a thickness of at leastthe first layer prior to attaching the lidding member to the basemember, where the cut line defines a break tab outwardly of the cut linethat is grippable by a user for peeling the lidding member away from thebase member to provide access to the cavity. Creating the perimeterportion may comprise forming a region of increased thickness using thepolyethylene emulsion of the first layer. Creating the cut line maycomprise creating the cut line between the pressure sensitive adhesiveand the perimeter portion, such that the lidding member separates fromthe base member at an interface disposed between the first layer and thebase member on an outward side of the cut line and at an interfacedisposed between the pressure sensitive adhesive and the first layer atan inward side of the cut line.

In other cases, creating the perimeter portion may comprise applyingpermanent adhesive to a perimetral region of the first layer such thatthe permanent adhesive is disposed adjacent to the outer edge of thepressure sensitive adhesive. A frangible layer may be created betweenthe adhesive layer and the first layer, where the cut line extendsthrough a thickness of the first layer outwardly of the exterior edge ofthe flange so as to define the break tab. In other embodiments, afrangible layer may be created between the first layer and the flange ofthe base member, where the cut line extends through a thickness of thefirst layer in a location corresponding to an interface between thepressure sensitive adhesive and the perimeter portion, such that thelidding member is separable from the base member at the frangible layeron an outward side of the cut line and at an interface disposed betweenthe pressure sensitive adhesive and the first layer at an inward side ofthe cut line.

In some embodiments, an ink layer may be applied on an inner surface ofthe second layer between the pressure sensitive adhesive and the secondlayer. Additionally or alternatively, the lidding member may be heatsealed to the base member in a location corresponding to the perimeterportion.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference willnow be made to the accompanying drawings, which are not necessarilydrawn to scale, and wherein:

FIG. 1 is a perspective view of a package with a base member and alidding member in the closed position;

FIG. 2 is a perspective view of the package of FIG. 1 in a partiallyopen position;

FIG. 3 is a top view of a conventional package;

FIG. 4 is a close up view of the conventional package of FIG. 3 showingchannels extending from an interior edge of the flange to an exterioredge of the flange of the package;

FIG. 5 is a top view of a lidding member of a package with a reinforcedperimeter portion according to an example embodiment;

FIG. 6 is a close up view of the package of FIG. 5 showing thereinforced perimeter portion blocking the channels from extending fromthe interior edge of the flange to the exterior edge of the flange ofthe package according to an example embodiment;

FIG. 7 is a partial schematic cross-sectional view of a lidding memberwith a reinforced perimeter and a base member in a closed positionaccording to an example embodiment;

FIG. 8 is a partial schematic cross-sectional view of the lidding memberwith the reinforced perimeter and the base member of FIG. 7 in an openposition according to an example embodiment;

FIG. 9 is a partial schematic cross-sectional view of a lidding memberwith a reinforced perimeter and a base member in a closed positionaccording to another example embodiment;

FIG. 10 is a partial schematic cross-sectional view of the liddingmember with the reinforced perimeter and the base member of FIG. 9 in anopen position according to an example embodiment;

FIG. 11 is a partial schematic cross-sectional view of a lidding memberwith a reinforced perimeter and a base member in a closed positionaccording to another example embodiment;

FIG. 12 is a partial schematic cross-sectional view of the liddingmember with the reinforced perimeter and the base member of FIG. 11 inan open position according to an example embodiment;

FIG. 13A is a perspective view of the package having a shakerconfiguration with a base member and a lidding member in the closedposition according to an example embodiment;

FIG. 13B is a perspective view of a package of FIG. 13A in the partiallyopen position according to another example embodiment;

FIG. 14 is a partial schematic cross-sectional view of the liddingmember with the reinforced perimeter and the base member of FIGS. 13Aand 13B in the closed position according to another example embodiment;and

FIG. 15 is a partial schematic cross-sectional view of the liddingmember with the reinforced perimeter and the base member of FIGS. 13Aand 13B in the open position according to an example embodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention now will be described more fully hereinafter withreference to the accompanying drawings in which some but not allembodiments of the inventions are shown. Indeed, these inventions may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

As noted above, and with reference to FIGS. 1 and 2, some packages forholding food items (e.g., refrigerated meats and cheeses) include a basemember 10 and a lidding member 20 that is attached to the base memberand is configured to be peeled away from the base member (as shown inFIG. 2) to provide access to a cavity 30 in which the package contentsare stored. The lidding member 20 may, for example, be secured to thebase member 10 (at least in some locations) by a layer of pressuresensitive adhesive (PSA), such that in some embodiments the liddingmember 20 may be re-adhered to the base member 10 by moving the liddingmember back into contact with the base member.

In conventional packages having PSA 40 at an interface between thelidding member 20 and the base member 10, the PSA is applied to thelidding member 20 such that the PSA extends between an interior edge 12of the base member and an exterior edge 14 of the base member when thepackage is closed, as shown in the top view depicted in FIG. 3. Whensuch conventional packages are in a refrigerated environment, it hasbeen observed by the inventors that stresses are created at theinterface between the base member 10 and the lidding member 20, whichcan create channels 50 in the PSA 40 (e.g., between the PSA and the basemember), as illustrated in FIG. 4. For example, cut lines made in thelidding member to facilitate opening of the package and/or re-sealingand tamper evident features can facilitate formation of channels bycreating areas of localized stresses. When such channels 50 extend fromthe interior edge 12 of the base member 10 to the exterior edge 14 ofthe base member, as depicted in FIG. 4, liquids contained in the cavity30 can escape to the package exterior via the channels 50, causing leaksand compromising the aesthetics, cleanliness, integrity, hermaticity,and/or overall appeal of the package to a potential consumer.

Through ingenuity and hard work, the inventors have developed are-sealable flexible package that includes a reinforced perimeterportion 60 of the lidding member 20 that acts as a blockade or barrierto such channels 50, such that even if such channels form, the channels50 are prevented from extending to the exterior edge 14 of the basemember, as shown in FIGS. 5 and 6. As a result, liquids stored insidethe package do not have a path to reach the package exterior and arethus contained within the package, despite the formation of the channels50. Similarly, oxygen, moisture, and other things that may be present inthe environment of the package do not have a path to enter into andcompromise the contents of the package.

Various structures and methods of providing the perimeter portion 60 arecontemplated, based on the types of materials used for the base member10 and/or the lidding member 20, the environment the package is designedto withstand (e.g., refrigerated or room temperature), differentprocesses the package will undergo (e.g., retort), and the type of sealused to secure the lidding member 20 to the base member 10 (e.g., heatseal or compressible seal). Regardless of the particular materials orconstruction of the perimeter portion 60, however, embodiments of theinvention described below with reference to FIGS. 7-15 provide aflexible package that includes a base member 10 that defines a cavity 30configured to receive an item or product therein, as shown in FIGS. 1and 2 (where the item stored within the cavity is not shown for clarityof the explanation). The base member 10 may include a flange 15 (e.g.,an outwardly extending flange of a tray or tub as shown in FIGS. 7-12 ora bead or rim of a composite can or cylindrical container as shown inFIGS. 13A-15), and the flange may define an exterior edge 14.

The package may further include a lidding member 20 that is configuredto be attached to the base member 10 to cover the cavity 30 and maintainthe item within the base member. The lidding member 20 may be configuredto be peeled away from the base member 10 to provide access to thecavity 30 and may be configured to be re-sealed to the base member 10 insome cases.

As described in greater detail below with respect to each embodiment,the lidding member 20 may comprise a first layer 70 that is configuredto engage the flange 15 of the base member 10 and that extends at leastto the exterior edge 14 of the flange. In some cases, as shown in FIGS.7-13B, for example, at least a portion of the first layer may extendpast (e.g., farther outward of) the exterior edge 14 of the flange 15,such as when the lidding member 20 forms a break tab 25 configured to begripped by the user to facilitate peeling of the lidding member 20 awayfrom the base member 10.

The lidding member 20 may further comprise a second layer 80 that islaminated to the first layer 70 via an adhesive layer 45. The adhesivelayer 45 may include one or more adhesive portions, including, forexample, a PSA portion 40 and/or another adhesive portion that isconfigured to separate from the first layer 70 when the lidding member20 is peeled away from the base member 10. Other portions of theadhesive layer 45 (e.g., portions configured to maintain the first layer70 laminated to the second layer 80) may include a permanent adhesiveportion 41. The adhesive portions (e.g., the PSA portion 40 and thepermanent adhesive portion 41) may, in some cases, be created viapattern printing. Cut lines 23 may be provided to allow portions of thefirst layer 70 to be lifted up with the lidding member 20 and otherportions 71 to remain with the base member 10, as described in greaterdetail below.

In some embodiments, such as those depicted in FIGS. 7-15, the liddingmember 20 may also comprise an ink layer 90 disposed on an inner surface82 of the second layer 80, between the adhesive layer 45 and the secondlayer 80. The ink layer 90 may, for example, include colors, designs,and/or printed indicia that can be viewed by a consumer through thesecond layer 80, such as to provide information on the item containedinside the package and/or to make the package more desirable forpurchase by a potential consumer. The PSA portion 40 of the adhesivelayer 45 may have a propensity to remain with the ink layer 90 due tothe chemical properties of each, such that when the lidding member 20 ispeeled away from the base member 10, the PSA has a tendency to stay withthe lidding member rather than with the portions 71 of the first layer70 that remain attached to the base member 10, as described below.

Finally, as described in greater detail below with respect to eachparticular embodiment, the lidding member 20 may further comprise aperimeter portion 60 that is adjacent to an outer edge 48 of the PSAportion 40 (e.g., in abutting contact with the PSA or separated from thePSA by a cut line), such that the PSA is spaced inwardly from theexterior edge 14 of the flange 15 by the perimeter portion 60.

In one embodiment, shown in FIGS. 7 and 8, for example, the base member10 may be formed of a low density polyethylene (LDPE) material, a highimpact polystyrene (HIPS) material, or other compatible material, andthe perimeter portion 60 may be made of a polyethylene (PE) emulsion. Inparticular, the first layer 70 of the lidding member 20 may comprise thePE emulsion, and the perimeter portion 60 may be defined by the firstlayer 70. The second layer 80 may comprise polyethylene terephthalate(PET) or one or more barrier films in some embodiments. An ink layer 90may be printed on an inner surface 82 of the second layer 80, betweenthe adhesive layer 45 and the second layer 80.

Thus, as depicted in FIGS. 7 and 8, the PE material of the first layer70 may be thicker (e.g., in a direction away from the flange 15) in thearea of the perimeter portion 60 than in the area between the flange 15and the PSA portion 40, such that an inner edge 62 of the perimeterportion 60 is adjacent the outer edge 48 of the PSA portion 40.Accordingly, as described above, the adjacency of the PE material in theperimeter portion 60 with respect to the outer edge 48 of the PSAportion 40 of the adhesive layer 45 can prevent any channels that formbetween the PSA and the underlying PE of the first layer 70 fromextending outwardly of the outer edge 48, thereby keeping any leaks fromreaching the exterior edge 14 of the base member 10.

The lidding member 20 may be affixed to the base member 10 by heatsealing along the perimetral edge of the lidding member/base memberinterface, e.g., in a location corresponding to a location of theperimeter portion 60. Accordingly, the package of FIGS. 7 and 8 may beopened by a user by creating a failure or breakage within the PEmaterial of the first layer. For example, the force of a user pullingupward (with respect to the depicted embodiment of FIGS. 7 and 8) on thelidding member 20 may cause the first layer 70 to fracture at aninterface of the first layer with the ink layer 90 and/or the secondlayer 80. In other cases, the fracture may occur between the first layer70 and the flange 15.

In some embodiments, as shown in FIGS. 7 and 8, the lidding member 20may comprise a cut line 22 between the PSA portion 40 and the perimeterportion 60. To facilitate opening of the package in this cut line 22may, for example, extend at least partially through a thickness of thefirst layer 70, between the ink layer 90/the second layer 80 and thebase member 10, such that the lidding member 20 separates from the basemember 10 at an interface disposed between the first layer 70 and thebase member 10 on an outward side of the cut line 22 and at an interfacedisposed between the PSA and the first layer at an inward side of thecut line, as shown in FIG. 8. In this regard, an inward portion 71 ofthe first layer 70 may remain attached to the flange 15 of the basemember 10, whereas the PSA portion 40 and the portion of the first layer70 corresponding to the perimeter portion 60 may remain with the liddingmember 20. Accordingly, the lidding member 20 may be re-sealable to thebase member 10 upon re-application of the lidding member to the flange15 of the base member to bring the PSA portion 40 back into contact withthe corresponding inward portion 71 of the first layer 70.

With respect to this and other embodiments described herein, as usedherein, the term cut line refers to a cut line that may be a cut that ismechanically formed (e.g., a die cut made by a blade), made by a laser(such as a laser score line), or made in any other suitable manner. Instill other cases, the cut line may be a line of weakness, such as a cutthat does not go completely through respective layer of material, or aseries of perforations. In some embodiment, such as the embodimentsdescribed herein, the cut line may be a rear cut line (e.g., a cut linethat is formed on one side of the lidding member 20 only, such as theside that is later attached to the base member 10). By forming a cutline in this manner (e.g., on the first layer side of the liddingmember), one or more barrier films may be used as the second layer 80,and one or more barrier films may be used as the second layer, wheresuch barrier films would remain intact and untouched by the rear cutlines, thereby increasing the structural integrity of the package.

Moreover, additional cut lines 23 may be provided inward of the cut line22 to ensure that other portions of the first layer, e.g., are peeledaway from the base member 10 when the lidding member 20 is removed, asdescribed above. In this way, portions of the first layer overlaying thecavity 30 may be moved away from the base member 10 to allow a user toaccess the cavity and its contents. For example, as noted above portionsof the first layer 70 may be adhered to the second layer 80 (and/or theink layer 90) via permanent adhesive 41 in a location corresponding tothe location of the cavity 30, and additional cut lines 23 may beprovided along an outermost perimeter of the permanent adhesive 41 toallow that portion of the first layer to be peeled away from the cavity30.

Regardless of how it they are formed, the cut lines 22, 23 may beconfigured (e.g., sized and shaped) to facilitate a user's opening ofthe package (e.g., via peeling of the lidding member 20 from the basemember 10). For example, the cut line 22 may be positioned so as toprovide a break tab 25 on the lidding member 20 to allow the user tomore easily grip the lidding member material and peel the lidding memberaway from the base member 10. For example, in some embodiments as shownin FIGS. 7 and 8, the first layer 70 and the perimeter portion 60 mayextend outwardly past the exterior edge 14 of the flange 15 of the basemember 10 and may define the break tab 25. Thus, the undercut formedbetween the first layer 70 and the flange 15 may provide an access areafor the consumer to grip the lidding member 20 and peel it away from thebase member 10.

Although in the embodiment described above and shown in FIGS. 7 and 8the perimeter portion 60 is defined by a thicker portion of the firstlayer 70, the perimeter portion 60 in other embodiments may be made of adifferent material and may be distinct from the first layer 70. Forexample, in the embodiment illustrated in FIGS. 9 and 10, the perimeterportion 60 comprises permanent adhesive. The base member 10 may, in suchembodiments, comprise polypropylene (PP), and the lidding member 20 may,in turn, also comprise a form of PP to facilitate sealing of the liddingmember 20 to the flange 15 of the base member 10 (e.g., via heat sealingas described above). For example, the lidding member 20 may comprisecast polypropylene (CPP), oriented polypropylene (OPP), or metalizedoriented polypropylene (mOPP), among other materials. The second layer80 may comprise polyethylene terephthalate (PET) or one or more barrierfilms in some embodiments. An ink layer 90 may also be provided betweenthe adhesive layer 45 and the second layer 80, as described above.

To facilitate a controlled separation of the lidding member 20 from thebase member 10, a frangible layer 75, which may be a weakened skin layerof the base member 10 or of the first layer 70 of the lidding member 20,may be provided. The frangible layer 75 may, in some cases, be a skinlayer that is disposed on a coextrudeable sealant film or a weakenedheat seal coating disposed in the heat seal area of the package, on thefirst layer 70 or the material forming the base member 10, such as acoating or sealant applied to the material that is configured to allowthe first layer 70 to be separated from the adhesive layer 45 (e.g., atthe permanent adhesive portions 41 of the adhesive layer 45). Thefrangible layer 75 may, e.g., include a contaminant material, such asButene Copolymer or polyButylene to create a weakened layer of material.

In the embodiment of FIGS. 9 and 10, for example, a frangible layer 75is provided at the interface between the first layer 70 and the adhesivelayer 45, as shown. In some cases, the frangible layer 75 may extend thefull length between an inner edge 47 of the PSA portion 40 and an outeredge 28 of the lidding member 20, as shown in FIGS. 9 and 10, whereas inother embodiments the frangible layer 75 may extend from the inner edge47 of the PSA portion only part of the way towards the outer edge 28,such as only to the vicinity of the break tab 25. Due to the presence ofthe frangible layer 75, permanent adhesive portions of the adhesivelayer 45 and/or the perimeter portion 60 that join the first layer 70 tothe second layer 90 will cause the layers 70, 90 to separate at thefrangible layer 75 (e.g., by fracturing the frangible layer), whereasthe PSA portions 40 joining the two layers 70, 90 may simply pull offthe surface of the frangible layer 75, without necessarily fracturingthe frangible layer or the surrounding structures.

Furthermore, in some embodiments, the lidding member 20 may comprise acut line 22 extending through a thickness of the first layer 70 (e.g.,in a direction away from the flange 15 and extending between the flangeand the adhesive layer 45). The cut line 22 may be disposed outwardly ofthe exterior edge 14 of the flange 15 so as to define the break tab 25.The bond between the permanent adhesive of the perimeter portion 60 andthe material of the first layer 70 in the area of the break tab 25 insuch embodiments may be stronger than the bond between the PSA portion40 and the corresponding portion of the first layer, such that when auser grips the break tab 25 and pulls the lidding member 20 in adirection away from the base member 10, a controlled break between theadhesive layer 45 and the first layer 70 occurs inwardly of the cut line22, allowing the lidding member 20 to be peeled away from the basemember 10. In this regard, an inward portion 71 of the first layer 70may remain attached to the flange 15 of the base member 10, whereas thePSA portion 40 and the perimeter portion 60 (e.g., the permanentadhesive) may remain with the lidding member 20. Accordingly, thelidding member 20 may be re-sealable to the base member 10 uponre-application of the lidding member to the flange 15 of the base memberto bring the PSA portion 40 back into contact with the correspondinginward portion 71 of the first layer 70. As described above with respectto FIGS. 7 and 8, one or more of the first layer 70, adhesive layer 45,ink layer 90, and/or second layer 80 may extend inwardly from the flange15, and additional cut lines 23 may be provided as shown to ensure thatthe cavity is adequately opened to provide access to the items containedinside the package.

In still other embodiments, the frangible layer 75 may be disposed at aninterface between the first layer 70 and the flange 15 of the basemember 10, as shown in FIGS. 11 and 12, such as by creating a weakenedskin layer of the flange using a method similar to that described abovewith respect to the first layer 70. As with the embodiment of FIGS. 9and 10, the base member 10 may be made of a PP material, the first layer70 may be made of CPP, and the second layer 80 may comprise polyethyleneterephthalate (PET) or one or more barrier films in some embodiments. Anink layer 90 may be provided between the adhesive layer 45 and thesecond layer 80. The perimeter portion 60 may comprise permanentadhesive, and the lidding member 20 may comprise a cut line 22 extendingthrough a thickness of the first layer 70 (e.g., in a direction awayfrom the flange 15) in a location corresponding to an interface betweenthe PSA portion 40 and the perimeter portion 60 to define the break tab25. The cut line 22 may, for example, extend at least partially througha thickness of the first layer 70 between the base member 10 and theadhesive layer 45 (and in some embodiments may extend at least partiallythrough the adhesive layer, such as at or near an interface between thePSA 40 and the adjacent permanent adhesive or through one or the other).

In this way, the lidding member 20 may be configured to be separablefrom the base member 10 at the frangible layer 75 on an outward side ofthe cut line 22, as depicted in FIG. 12, and at an interface disposedbetween the PSA portion and the first layer 70 at an inward side of thecut line. As described above with respect to the embodiment of FIGS. 9and 10, the bond between the permanent adhesive of the perimeter portion60 and the material of the first layer 70 in the area of the break tab25 in such embodiments may again be stronger than the bond between thePSA portion 40 and the corresponding portion 71 of the first layer 70,such that when a user grips the break tab 25 and pulls the liddingmember 20 in a direction away from the base member 10, a controlledbreak between the adhesive layer 45 and the first layer 70 occursinwardly of the cut line 22 and between the first layer 70 and theflange 15 outwardly of the cut line 22, thereby allowing the liddingmember 20 to be peeled away from the base member 10. In this regard, aninward portion 71 of the first layer 70 may remain attached to theflange 15 of the base member 10, whereas the PSA 40 and the perimeterportion 60 (e.g., the permanent adhesive) may remain with the liddingmember 20. Accordingly, the lidding member 20 may be re-sealable to thebase member 10 upon re-application of the lidding member to the flange15 of the base member to bring the PSA 40 back into contact with thecorresponding inward portion 71 of the first layer 70. As with theembodiments described above, additional cut lines 23 may be provided inportions of the lidding member inward of the portions shown tofacilitate opening of the package

Aspects of the embodiments described above with respect to FIGS. 7-12may, in some cases, be applied to other types of packages that do notinclude a base member configured in the shape of a tub. Turning to FIGS.13A-15, for example, a cylindrical shaker-type of package may beprovided that incorporates a perimeter portion for preventing orreducing the occurrence of leaks (into or out of the package) asdescribed above with respect to other embodiments.

In the embodiment shown in FIGS. 13A-15, for example, the base member 10comprises a cylindrical container, which may be a composite can with apolymer (e.g., PP) sealant or an injection molded PP container. Thelidding member 20 in the depicted embodiment may be configured such thatwhen peeled away from the base member 10, at least a portion of thefirst layer 70 of the lidding member remains attached to and covers theopened end 17 of the cylindrical container. In such embodiments, thefirst layer 70 may define holes 77, such that the package can be used asa strainer or shaker (e.g., for dispensing the contents of the packageby inverting the package after peeling away the lidding member andallowing the contents to fall out via the holes), as described ingreater detail below.

With reference to FIGS. 14 and 15, for example, the first layer 70(which may be made of CPP in some embodiments) may be attached (e.g.,via heat sealing as described above) to a rim or flange 15 of thecylindrical base member 10, as shown. The first layer 70 may have holes77 cut through a thickness of the film to allow product to be dispensedupon opening of the package. A frangible layer 75 may be provided in thematerial of the first layer 70 at an interface between the first layer70 and an adhesive layer 45, where the adhesive layer 45 includes anarea of PSA 40 (e.g., in a central region corresponding to the locationof the holes 77 defined in the first layer 70).

As described above with respect to the embodiment of FIGS. 9-12, theperimeter portion 60 in the embodiment depicted in FIGS. 13A-15 may, insome cases, comprise a permanent adhesive. Thus, the permanent adhesiveforming the perimeter portion 60 may be in the shape of a ring when thepackage is viewed from the top. Furthermore, in some embodiments, an inklayer 90 may be applied to an inner surface 82 of the second layer 80,where the second layer 80 is made of PET material or a barrier film. Instill other embodiments, the second layer 80 may comprise a laminatefilm (not shown) that has more than one film layers laminated together.For example, the second layer 80 may comprise an oxygen barrier filmthat is laminated to a moisture barrier film.

When the lidding member 20 is peeled away from the base member 10, suchas via a user pulling on a break tab 25 (FIG. 13A), the adhesion betweenthe permanent adhesive of the perimeter portion 60 and the frangiblelayer 75 may serve to cause a failure of the frangible layer in thoselocations that are adhered to the permanent adhesive. In other portionsof the lidding member 20, such as where the PSA portion 40 is adhered tothe frangible layer 75, the adhesive layer 45, ink layer 90, and secondlayer 80 may be peeled off the first layer 70 due to the low adhesivestrength of the PSA to the frangible layer and/or underlying material ofthe first layer, as shown in FIG. 15. Thus, by peeling the liddingmember 20 away from the base member 10, the holes 77 in the first layer10 may be exposed, and product can be dispensed from the package. Tofacilitate the proper peeling of the lidding member, cut lines 22 may beprovided in the adhesive layer, such as a cut line formed between theperimeter portion 60 and the PSA portion 40.

In any of the embodiments pictured in FIGS. 7-15 and described above,one or more additional packaging features may be used in conjunctionwith those described above. For example, tamper evident features may beprovided to allow a consumer to visually identify whether a package hasbeen previously opened. With respect to the embodiment of FIGS. 13A-15,for example, the break tab 25 may initially be tacked on (e.g., viaglue) to an outer surface 13 of the base member 10, as shown in FIG.13B. A user opening the package for the first time would pull the breaktab 25 to detach it from the outer surface 13 and continue peeling thelidding member 20 away from the base member 10 to open the package. Onceopened, although the lidding member 20 may be re-attachable to the basemember 10 via the PSA 40, the detached state of the break tab 25 wouldserve as a visual indication that the original seal on the package hasbeen broken.

In addition to the different embodiments of packages described abovewith respect to FIGS. 7-15, embodiments of a method of manufacturing aflexible package are also provided. Embodiments of the method includeforming a base member having a cavity configured to receive an itemtherein and a flange, where the flange defines an exterior edge. A firstlayer of material may be laminated to a second layer of material to forma lidding member that is attached to the base member to form thepackage. For example, the lidding member may be formed by applying apressure sensitive adhesive between the first and the second layers andcreating a perimeter portion between the first and second layers that isdisposed adjacent to an outer edge of the pressure sensitive adhesive,such that the pressure sensitive adhesive is spaced inwardly from theexterior edge of the flange.

In some cases, the lidding member may be attached to the base member ata location corresponding to the perimeter portion, such that the liddingmember covers the cavity and maintains the item within the base member.At least a portion of the lidding member may be configured to be peeledaway from the base member to provide access to the cavity and may befurther configured to be re-sealed to the base member via the pressuresensitive adhesive, as described above.

In some embodiments, a cut line may be created through a thickness of atleast the first layer prior to attaching the lidding member to the basemember. The cut line may define a break tab outwardly of the cut linethat is grippable by a user for peeling the lidding member away from thebase member to provide access to the cavity, as described above.

As provided in detail above, the perimeter portion may be created invarious ways depending on the materials involved, the types of packagesbeing made and their proposed uses, etc. The perimeter portion may, forexample, be created by forming a region of increased thickness of thefirst layer, such as using a polyethylene emulsion. The cut line may becreated between the pressure sensitive adhesive and the perimeterportion, such that the lidding member separates from the base member atan interface disposed between the first layer and the base member on anoutward side of the cut line and at an interface disposed between thepressure sensitive adhesive and the first layer at an inward side of thecut line.

In other cases, the perimeter portion may be created by applyingpermanent adhesive to a perimetral region of the first layer such thatthe permanent adhesive is disposed adjacent to the outer edge of thepressure sensitive adhesive. A frangible layer may be created betweenthe adhesive layer and the first layer, and the cut line may extendthrough a thickness of the first layer outwardly of the exterior edge ofthe flange so as to define the break tab.

In other embodiments, a frangible layer may be created between the firstlayer and the flange of the base member, and the cut line may extendthrough a thickness of the first layer in a location corresponding to aninterface between the pressure sensitive adhesive and the perimeterportion, such that the lidding member is separable from the base memberat the frangible layer on an outward side of the cut line and at aninterface disposed between the pressure sensitive adhesive and the firstlayer at an inward side of the cut line.

An ink layer may, in some cases, be applied on an inner surface of thesecond layer between the pressure sensitive adhesive and the secondlayer. Moreover, the lidding member may be heat sealed to the basemember in a location corresponding to the perimeter portion to attachthe lidding member to the base member.

Embodiments of the package are described above having differentmaterials and, in some cases, different structures and methods offorming the perimeter portion. Although some such structures andfeatures are described with respect to a particular embodiment, it isunderstood that various combinations of the features may be applied toother embodiments described herein. For example, each of the embodimentsof FIGS. 7-15 may configured to include a tamper evident feature, suchas the tamper evident feature described with respect to FIGS. 13A-15. Inaddition, as noted above, some of the figures described above have beensimplified for purposes of explanation, such that not all portions ofthe components, including portions of the base member, first and secondlayers of the lidding member, die cuts, adhesive layers, etc. are shown.It is understood that portions of these components may be configured toimpart additional desirable qualities to the package, such as tofacilitate opening and closure of the package, re-sealability, barrierproperties, etc.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

What is claimed is:
 1. A flexible package comprising: a base memberdefining a cavity configured to receive an item therein, the base membercomprising a flange, wherein the flange defines an exterior edge; and alidding member configured to be attached to the base member to cover thecavity and maintain the item within the base member, wherein the liddingmember is configured to be peeled away from the base member to provideaccess to the cavity and is configured to be re-sealed to the basemember, wherein the lidding member comprises: a first layer configuredto engage the flange of the base member and extending at least to theexterior edge of the flange, a second layer laminated to the first layervia an adhesive layer, wherein the adhesive layer comprises a pressuresensitive adhesive in a first portion spaced inwardly from the exterioredge of the flange, wherein the pressure sensitive adhesive isconfigured to separate from the first layer when at least a portion ofthe lidding member is peeled away from the base member, and a permanentadhesive in a perimeter portion adjacent an outer edge of the pressuresensitive adhesive and extending to at least the exterior edge of theflange, and a frangible layer between the first layer and the flange ofthe base member in at least the perimeter portion, wherein the frangiblelayer is configured to fracture laterally through at least a portion ofits thickness, in the perimeter portion, when at least a portion of thelidding member is peeled away from the base member and the first layerand the flange of the base member separate.
 2. The flexible package ofclaim 1, wherein the lidding member comprises a cut line extendingthrough a thickness of the first layer in a location corresponding to aninterface between the pressure sensitive adhesive and the perimeterportion, wherein the cut line extends at least partially through athickness of the first layer between the base member and the adhesivelayer, such that the lidding member is separable from the base member atthe frangible layer on an outward side of the cut line and at aninterface disposed between the pressure sensitive adhesive and the firstlayer at an inward side of the cut line.
 3. The flexible package ofclaim 1, wherein the lidding member further comprises an ink layerdisposed on an inner surface of the second layer between the adhesivelayer and the second layer.
 4. The flexible package of claim 1, whereinthe second layer of the lidding member comprises a barrier material. 5.The flexible package of claim 1, wherein the frangible layer comprises aweakened skin layer of the base member or the first layer of the liddingmember.
 6. The flexible package of claim 5, wherein the skin layercomprises a coextrudable sealant film or a weakened heat seal coating.7. The flexible package of claim 1, wherein the frangible layercomprises a contaminant material.
 8. The flexible package of claim 1,wherein the bond between the permanent adhesive of the perimeter portionand the material of the first layer is stronger than the bond betweenthe pressure sensitive adhesive and the first layer.
 9. The flexiblepackage of claim 1, wherein the fracture comprises a controlled break.10. The flexible package of claim 1, wherein the frangible layer isconfigured such that at least a portion of the frangible layer remainsaffixed to the first layer and a portion of the frangible layer remainsaffixed to the base member when the lidding member is peeled away fromthe base member.
 11. A method of manufacturing a flexible package, themethod comprising: forming a base member having a cavity configured toreceive an item therein and a flange, wherein the flange defines anexterior edge; laminating a first layer of material to a second layer ofmaterial to form a lidding member by: applying a pressure sensitiveadhesive in a first portion spaced inwardly from the exterior edge ofthe flange, between the first and the second layers, and applying apermanent adhesive in creating a perimeter portion between the first andsecond layers that is disposed adjacent to an outer edge of the pressuresensitive adhesive and extends to at least the exterior edge of theflange; and providing a frangible layer between the first layer and theflange of the base member in at least the perimeter portion attachingthe lidding member to the base member at a location corresponding to theperimeter portion, such that the lidding member covers the cavity andmaintains the item within the base member, wherein at least a portion ofthe lidding member is configured to be peeled away from the base memberto provide access to the cavity and is configured to be re-sealed to thebase member via the pressure sensitive adhesive, and wherein thefrangible layer is configured to fracture laterally through at least aportion of its thickness, in the perimeter portion, when the liddingmember is peeled away from the base member.
 12. The method of claim 11further comprising creating a cut line through a thickness of at leastthe first layer prior to attaching the lidding member to the basemember, wherein the cut line defines a break tab outwardly of the cutline that is grippable by a user for peeling the lidding member awayfrom the base member to provide access to the cavity.
 13. The method ofclaim 11 further comprising applying an ink layer on an inner surface ofthe second layer between the pressure sensitive adhesive and the secondlayer.
 14. The method of claim 11 further comprising heat sealing thelidding member to the base member in a location corresponding to theperimeter portion.